Bandar Imam Petrochemical Complex Revamping Project
After almost 34 years of development of the installation, including the eight year period of the Iran-Iraq war in the area, the plant remains live and operational. The Bandar Imam Petrochemical Complex (BIPC) is one of the largest industrial undertakings in Iran and relies on a pneumatic control system for the operation of most of the plants including Olefine, HDPE, PP, NF and eight other units.
Due to the ongoing spare parts demand of the complex, which is now presenting difficulties, and bearing in mind the quality of the products, BIPC management decided to change the control system philosophy from pneumatic to the latest available technology in process automation in the form of Foundation Fieldbus. Finally a combined solution of DCS and FCS for the control system – referred to as the 'hybrid solution' – was selected and specified.
In 2002 a consortium of three local companies started basic detail design for the complex and Pepperl+Fuchs monitored the project from its early stages. Most of the petrochemical applications are located in Zone 1 and will be explosion protected by either FISCO or the high power trunk concept. Since there was little familiarity with the high power trunk solution at the time, Pepperl+Fuchs trained the project engineers in the hazardous area application of fieldbus solutions. Finally, it was decided to specify three FieldBarriers per segment to connect approximately ten devices, with 20 % additional spare FieldConnex Temperature Multi-Inputs in order to allow the existing thermocouples and RTD's to communicate with the new system.
During 2004 the DCS/FCS component of the first plant was awarded to ABB, based on the Pepperl+Fuchs Power Hub solution. The components were delivered in 2006 and the Olefin unit is now undergoing revamping by the local contractor.
Subsequently, the HDPE plant development was announced and in a very tough competition of three control systems a local contractor was awarded this project based on Honeywell controllers and Pepperl+Fuchs LB Remote I/O systems, in addition to Power Hubs and FieldBarriers. The solution was gradually adapted to meet the end user's requirements and specifications.
The BIPC team found this solution very useful and effective, with maximum reliability, and decided to continue all future projects by either revamping the existing plant or constructing a completely new unit in the complex on the same conceptual principles. The team is due to annually complete a revamping project at the Bandar Imam complex and Pepperl+Fuchs has been named the preferred supplier of the Foundation Fieldbus products involved. Currently, the Advanced Diagnostic Module is being eagerly accepted by the end user and they are about to integrate the physical layer diagnostic capability in their projects.